Stevebsy's 5MT swap thread, Start date 8-4-2019

[Stevebsy]

Finally I'm making some progress.
Just picked up a 06 Saaburu 2-5X Aero with hail lumps and a 3 cylinder engine last night. This is great because I'll have every part I should need to make this happen!

The transmission is the 3.7 ratio w/ .738 5th gear ratio, so it should turn about 2768 at 75 MPH.

Let the fun begin!

https://www.dropbox.com/s/l622npnp74...2108a.jpg?dl=0

[theflystyle]

Unrelated, but is it just me or the front left wheel has a chunk missing?

[huck369]

Originally Posted by Stevebsy

The transmission is the 3.7 ratio w/ .738 5th gear ratio, so it should turn about 2768 at 75 MPH.

Sounds like a good fit for a Grand Touring car!
Looking forward to seeing it finished!

[Stevebsy]

Wheeeeeeee
just a year later update:

5MT is in car, attached to engine
Pedalbox is in

Engine was resealed, new HG, etc.. when I had everything out.

Tonight I got back at it again after a long absence and started reconnecting the engine accessories.

Remaining items:
MT trans. mount fabrication
Extend shift rods
Remove AT shifter, install MT one
Hook up and bleed hyd. clutch
Sort out wiring mods required for NSS, etc..
Build new exhaust system to replace currently hacked together one.
Since one seat is out, remove the other one, then pull carpet and power wash so it isn't so nasty.

30th anniv. meet should be attainable lol

[huck369]

Originally Posted by Stevebsy

Wheeeeeeee
just a year later update:

5MT is in car, attached to engine
Pedalbox is in

Engine was resealed, new HG, etc.. when I had everything out.

Tonight I got back at it again after a long absence and started reconnecting the engine accessories.

Remaining items:
MT trans. mount fabrication
Extend shift rods
Remove AT shifter, install MT one
Hook up and bleed hyd. clutch
Sort out wiring mods required for NSS, etc..
Build new exhaust system to replace currently hacked together one.
Since one seat is out, remove the other one, then pull carpet and power wash so it isn't so nasty.

30th anniv. meet should be attainable lol

Nice, you're just one good day away from being done!

[wdb]

Progress! Great to hear.

[Stevebsy]

Update-
Shifter linkages extended today, took a couple tries to get it perfect and centered in the AT shifter trim opening..

Picked up a 2000 Outback MT drive shaft, so that will save a lot of work as it supposed to bolt right in and work.

Tomorrow will finish weld the linkages, paint them, then look at fabricating the trans rear mount. I've got the parts from the donor car, hoping I might be able to use them to reduce fabrication, we'll see....

[huck369]

You're getting there!

[Stevebsy]

Yee ha - almost there...

Today:
Swapped LSD into 3.7 rear diff. Somehow got the shims messed up, so I had to do the math of the FSM to the best of my ability. Didn't know how to figure out the Dimension E/F though. Got the backlash dialed in between .1 and .2mm per spec. (~.12) so I think I'll be ok....? Hope so

Installed 2000 Outback MT drive shaft, fits perfect
Finished installing my Trans mount for the rear. Mine is different to the 'standard' style one, but I think it'll work. Some uuuuuuuggggggly welds on there but it'll hold I'm pretty sure.

Finished the interior trim install around the shifter hole. Just need to modify the skirt thing a little bit to fit better inside the SVX cutout.

Attached up the slave cylinder and reconnected the brakes master cylinder

Attached the front exhaust section (manifold + resonator on each side) for some brief testing. Debating taking it to get a whole new system made up, or just patch what I have back together..

Tomorrow;
Alternator wiring upgrade
Reconnect engine harness
Reinstall radiator, heater hoses, fuel lines,
Bleed brakes & clutch
Fill fluids - engine, trans, diff, brake, clutch, coolant
Helicoil for starter bolt



I'll get some pictures tomorrow but hope to make vroom vroom noises by the afternoon

[Blacky]

Fantastic!

[wdb]

Vroom vroom?

[Stevebsy]

Yea nice vroom vrooming

Sounds good with just the first resonators hooked up Let it idle for about 10-15 min, got to temp, no gushing fluid leaks, nothing on fire, seems good.

Still got a few things left:
Replace leaking trans output shaft seal
Extend VSS wiring
Run NSS/Reverse wiring from trans into cabin, into 4eat plug
Run clutch switch wiring into 4EAT plug (same one as NSS)
Bleed Brakes
Replace DS Front CV axle
Install shifter trim boot
Reinstall enough of the exhaust to get it to a shop to redo a new one
Get it registered again

[huck369]

Hope you get it up the the Dragon Meet next Year!